PSI - Issue 56

ScienceDirect Structural Integrity Procedia 00 (2023) 000 – 000 Structural Integrity Procedia 00 (2023) 000 – 000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia

www.elsevier.com/locate/procedia

Procedia Structural Integrity 56 (2024) 41–48

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the SIRAMM23 organizers 10.1016/j.prostr.2024.02.035 2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the SIRAMM23 organizers 2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the SIRAMM23 organizers © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the SIRAMM23 organizers Abstract The Additive manufacturing (AM) process, especially laser powder fusion (LPBF), could print complex medical implants directly from computer-aided design (CAD) data. LPBF offers numerous benefits compared to traditional methods, such as efficient customized product development, complex shape creation, and lighter components that save time and costs. AM also have some challenges that are usually addressed, such as poor surface quality, physical properties, residual stresses and fatigue. These challenges prevent AM parts from being used in real-life applications. Surface roughness is a significant issue in many forms of additive manufacturing because of the layer-by-layer deposition process. This study aims to understand better the roughness generated during the laser powder bed fusion process. In LPBF, metal powders are melted by a focused laser beam to create each component layer. Despite its ability to produce fine details using a variety of metal powders, LPBF is one of the most widely used metal AM processes across various industries, including the automobile, aerospace, and medical fields. However, there are complex physical phenomena in LPBF that contribute to roughness. This study seeks to understand LPBF and explore post-processing techniques to improve the surface roughness of additively manufactured parts. The processing techniques, including traditional machining, wire electro-discharge machining, chemical anodizing, abrasive flow finishing and laser polishing, are customarily applied to resolve these issues. This study has complied with various post-processing techniques and their implementation. The effects of different post-processing techniques on additive-manufactured Al12Si are discussed in detail. Micro-milling significantly reduces surface irregularity topography, peaks and roughness. Micro-milling reduced average surface roughness (S a ) by up to 99% and a minimal increase in surface hardness compared to WEDMed, chemical anodizing, sandblasting, and as-printed parts. The study found that micro-milling is a promising approach for finishing complex metallic additively manufactured parts with minimal complexity. © 2023 The Authors. Published by ELSEVIER B.V. Abstract The Additive manufacturing (AM) process, especially laser powder fusion (LPBF), could print complex medical implants directly from computer-aided design (CAD) data. LPBF offers numerous benefits compared to traditional methods, such as efficient customized product development, complex shape creation, and lighter components that save time and costs. AM also have some challenges that are usually addressed, such as poor surface quality, physical properties, residual stresses and fatigue. These challenges prevent AM parts from being used in real-life applications. Surface roughness is a significant issue in many forms of additive manufacturing because of the layer-by-layer deposition process. This study aims to understand better the roughness generated during the laser powder bed fusion process. In LPBF, metal powders are melted by a focused laser beam to create each component layer. Despite its ability to produce fine details using a variety of metal powders, LPBF is one of the most widely used metal AM processes across various industries, including the automobile, aerospace, and medical fields. However, there are complex physical phenomena in LPBF that contribute to roughness. This study seeks to understand LPBF and explore post-processing techniques to improve the surface roughness of additively manufactured parts. The processing techniques, including traditional machining, wire electro-discharge machining, chemical anodizing, abrasive flow finishing and laser polishing, are customarily applied to resolve these issues. This study has complied with various post-processing techniques and their implementation. The effects of different post-processing techniques on additive-manufactured Al12Si are discussed in detail. Micro-milling significantly reduces surface irregularity topography, peaks and roughness. Micro-milling reduced average surface roughness (S a ) by up to 99% and a minimal increase in surface hardness compared to WEDMed, chemical anodizing, sandblasting, and as-printed parts. The study found that micro-milling is a promising approach for finishing complex metallic additively manufactured parts with minimal complexity. © 2023 The Authors. Published by ELSEVIER B.V. Structural Integrity and Reliability of Advanced Materials obtained through Additive Manufacturing (SIRAMM23) Effect of Post-processing Techniques on the Surface Roughness of Laser Powder Bed Fusion Processed AlSi12 Alloy Sai Kumar Balla a , Manjaiah Mallaiah a, *, Anand Kumar Subramaniyan b a Additive Manufacturing Laboratory, Department of Mechanical Engineering, National Institute of Technology, Warangal – 506004, India b Additive Manufacturing Research Laboratory, Department of Mechanical Engineering, Indian Institute of Technology, Jammu – 181221, India Structural Integrity and Reliability of Advanced Materials obtained through Additive Manufacturing (SIRAMM23) Effect of Post-processing Techniques on the Surface Roughness of Laser Powder Bed Fusion Processed AlSi12 Alloy Sai Kumar Balla a , Manjaiah Mallaiah a, *, Anand Kumar Subramaniyan b a Additive Manufacturing Laboratory, Department of Mechanical Engineering, National Institute of Technology, Warangal – 506004, India b Additive Manufacturing Research Laboratory, Department of Mechanical Engineering, Indian Institute of Technology, Jammu – 181221, India * Corresponding author. Tel.: +91-9740847669; E-mail address: Manjaiah.m@nitw.ac.in * Corresponding author. Tel.: +91-9740847669; E-mail address: Manjaiah.m@nitw.ac.in